Method of making light reflectors



Dec. 22, 1931. R. w. LUCE ET AL 1,837,720

I METHOD OF MAKING LIGHT REFLEQTORS Original Filed Sept. 5, 1929 nrromve y Patented Dec. 22, 1931 UNITED STATES PATENT OFFICE RICHARD W. LUGE OF MOUNTAINSIDE, AND LESLIE M. MERRILL, F MADISON, NEW JERSEY, ASSIGNOBS TO AMERICAN GASACCUMULATOR COMPANY, OF ELIZABETH, NEW JERSEY, A CORPORATION OF NEW JERSEY METHOD MAKING LIGHT REFLECTOR-S Original application filed September 5, 1929, Serial No. 390,480. Divided and this application filed December 26, 1930.

Our invention relates to the method of making light reflectors adapted for use as aids to traflic upon highways, streets and the like, the said reflectors being of a type or character which fits them for'use not only as stationary signs or signals upon highways and streets but also'for use upon automobiles and other like vehicles.

The method is particularly adapted to be 1 employed in the manufacture of'a light reflector having concentric circular light-reflecting areas, the surface of one circular area being located in displaced relation, front or provide a method novel in character by which a reflector embodying the above indicated characteristics may be manufactured expe ditiously and at a of expense.

Without reference to the further objects and advantages of the invention we shall now proceed with a detaileddescription of the said invention wherein other objects and advantages thereof either will be especially referred to or else will become apparent. To facilitate an understanding of the invention y it is desirable that reference be made to some form of mechanical construction by which the steps of the method may be performed in practice, and to that end we have designed an apparatus to which reference will be made, it being understood that the steps may be carried out by other forms of apparatus and that reference to apparatus is made for the purpose of facilitating the description of the invention and not by way of limitation thereof, I

In the drawings: Fig. 1 is a view in edge elevation of a-section of thin sheet metal which may be employed in the manufacture of the reflector;

Fig. 2 is a view in sectional elevation of a Serial No. 504,780.

die structure by means of which initial formation of the reflector is effected;

Fig. 3 1s atop plan .view of a section of a strip such as is illustrated in Fig. 1 following completed reflector, indicating certain steps of the process employed in the manufacture of the reflectors;

Fig. 8 is a vertical longitudinal sectional view of press including dies by which the final forming operation in the production of a reflector is effected;

Fig. 9 is an enlarged view of a fragmentary portion of the completed reflector;

Fig. 10 is a view of the ,reflector after the operation indicated in Fig. 8; and

Fig. 11 is a view in central vertical longitudinal section of the reflector embodying the invention.

It may be stated that while the'reflector as illustrated in. Fig. 11 is complete in so far as its reflecting qualities and characteristics are concerned, and rays of light which may impinge upon the concentrically arranged reflecting surfaces at the bottom of the reflector as shown in Fig. 11 are reflected thereby, yet, in actual practice it is customary and perhaps necessary to combine with the said reflector a condensing lens of ball or other form of .suitable material through which the impinging and reflected rays of light are adapted to pass in known manner.

In the production of reflectors embodying our invention we employ preferably long strips of suitable sheet metal, such as copper, a section of which is shown at 1 in Fig. 1. Strips of this character are supplied to and fed successively through a punch and die press, as indicated in Fig. 2, comprising a stationary member 2, the upper side of which is provided with a recess 3 which is circular in cross section and may be of a depth substantially as shown. The member 2 is also provided with an opening 3 of a shape such as that of the opening shown in the metal strip, as illustrated in Fig. 3.. The

forming punch member of the punch and die structure is shown at 4 with its lower end projecting into the recess 3. The said forming punch member 4 is carried upon .a head 5 of a reciprocatable member 6. The head 5 also supports in spaced relation to the forming punch 4 a cutting punch or element 7, located in alignment with the opening 3 'in the stationary member 2, and of the same shapein cross section as that of the said opening but with dimensions slightly less than those of the said opening so that it may enter the same as indicated. A draw plate 8 is also carried by the head 5, being supported upon the lower ends of rods 9, the upper ends of which extend through openings 10 provided in the said head. The said upper ends.

As has been stated already, metal strips.

which are relatively narrow, as indicated in Fig. 3, are fed through the punch and die device of a structure such as is shown in Fig.

2, the feeding thereof being from the right toward the left. Each strip is fed over the upper side of the member 2 and below the forming and cutting punches 4 and 7. Upon the descending movement of the head 5 the forming and cutting punches 4 and 7 likewise descend. The latter of these punches cuts out portions of the metal of the strip 1 at spaced intervals therein to leave openings of the shape indicated at 16 in Fig. 3. These openings correspond in shape-to the cross section area of the cutting punch 7 and the openings 3'. Simultaneously with the cuttin of the openings 16 the forming punch 4 escends and depresses the central portion of the metaliof the strip between adjoining openings '16 to form cup-like portions 17 which are surrounded by relatively wide flanges 18.-

These flanges are connected together by the narrow connecting strips 19 at the opposite edges of the structure, as shown in Fig. 3.-

After the completion of the operation, as

illustrated in Fig, 2 of the drawing, the por- I tion 17 preferably is subjected -first.to an annealing treatment, after which it is pickled in known manner to remove the scale therefrom. In Fig. 5 of the drawing we have illustrated in section a portion ofthe initially formed cup-like part, indicating by means of alternate projections and depressions 20 and 21 the roughness of the surfaces of the metal. After the pickling operation the strip embodying the initially formed cuplike portions is subjected toja bright diptreatment, which consists 1n the iminersion of the same in a liquid bath including suitable chemicals. The pickling and bright dipping. operations arequite common in methods or processes of this char} acter and need not be referred to or described in detail. It may be noted by reference to Fig. 6 that the result of the bright dipping operation is to modify somewhat the projections 2-0 by removing the outer or apical portions thereof. After the bright. dipping operation a very thin plate or coating of a suitablemetal such as silver is applied, preferably by electro-chemical deposition upon.

both sides of the initiaLcup-like structure. The presence of these silver coatings is indicated at 22 and 23 in Fig. 7 of the drawings. The same coatings are shown at 22 and 23 in Fig. 9 of the drawings after the initially formed cup-like portions have been subjected to the further pressing and forming operation indicated in Fig. 8 of the drawings.

In the structure as shown in Fig. 80f the drawings we have provided a stationary die member 25 terminating at its upper end in a projecting portion 26 of smaller" diameter ter of the portion 26 will be governed by the desired diameter of the inner portion 27 of the completed reflector, while the diameter of the outer portion of the member 25 will depend upon the desired diameter of the front portion 28 of the completed reflector. The upper or inner end of the portion 26 is provided than the lower portion thereof.- The diamewith a circular projection 30. The annular surface 3l upon the outer portion of the projection 26 and'also the outer surface 31 of the low projection 30 are spherical, so that the inner reflecting surfaces of the concentric por tions 32 and 33 of the completed reflector shown in Fig. 11 of the drawings are spherical. The upper reciprocatable portion 35 of the die isprovided with a recess 36 the inner surface 'offwhich is the counterpart of the outer surfaces of the projecting ortions 26 and 30 of the stationary die mem er 25. In

the operation of the die ress of Fig.8 an initially formed cup-shap the parts 17 and 18 is placed in position over the ,upper end of the member 25, whereupon the female die member 35 is moved downwardly so as to act upon and press the inner or rear end portion of the said cup-shaped.

member into form corresponding to the internal shape or configuration-of the recess 36 in the member 35 and the external configuration'or shape of the portions26 and 30 of the die member 25. f I

A pressing and, forming member 40 moves downward simultaneously with the member 35. The lower end portion of the member 40,

istubular, as indicated, and the inner edges of the lower'end thereof contact with the outmember comprising er portion of the flange 18 and bend the same contacts with the outer portion of the said I downwardly, as indicated at 41, so as to flange and bends and draws the same around form the outer or front portion 28 of the rethe outer edge of the shoulder 44 and presses flector of greater diameter than the inner or the same against the portion of the member rear portion 27 thereof. The member 40 con- 25 of larger diameter below the said shoulstitutes a drawing and shaping member and der 44. It will be understood also that at operates in the manner which will be apparthe beginning of its action upon the outer ent and clear to those skilled in the art. The portion of the said flange the connecting lower end of the member 40 operates to clamp strips .19 are severed, as above described. the outer portion of the flange 18 against the J ustprior to the-completion of the downupper side of a holding ring 42 which is supward movement of the member 40 the upper ported upon springs 43 in the usual known end of the projection 58 comes into contact manner. It will be noted that the portion 41 with the said member 40 at the upper end of is bent around the curved edge of a shoulder the opening 54 therein, so that during the 44 provided upon the member 25 and surlatter part of the operation of the dies the rounding the lower end of the projection-26. portions 32 and 33 of the reflector are sub- The presence of this shoulder and the cooperjected to high positively or unyieldingly exation of the circular open end of the member erted pressure, so that a polish is' imparted 40 therewith results in the formation of a to the inner spherical surfaces thereof correshoulder 45 in the completed reflector, as is sponding to the polish of the surfaces 31 and shown in Fig. 11 of the drawings. In the 31'. During that period the pressing outdownward movement of the member 40 the wardly or ,rearwardly of the portion 32 of Outer edge 46 of the lower end thereof 00- the reflector beyond the plane of the annular operating with the edge 47 of an opening 48 P rti n 33 hereof is completed.

in the block 49 operates to sever, as indicated The ph l surfaces 31 and 1' h v the at 50, the narrow connections 19 to'whichrefsame center, with radii of different lengths.

erence has b ad iou ly, Itfollows that the inner reflecting surfaces The member 35 of the dieismounted withinf he corresponding portions 32 and 33 of the opening 54 in the lower end of the mem, the reflector also have the same center, with ber 40 and is movable in'the said pening radii of different lengths. From that araxially thereof, The member 35 t minates rangement it follows that when the reflector at its upper end in an enlarged or head por- 1s embodied in a device for use 1119011 hightion 55 the lower end of which is tapered, as ways, streets and the like, and is combined indicated at 56, t for a ta d h ld with a condensing lens of ball or other form which is adapted t a e with a i il ly as above indicated and assuming that the tapered shoulder 57 provided interiorly of the llleldellt r y of a beam of light m a hollow lower end of the member 40, as shown. tent Source focus upon the reflecting Sur- Th upper d f th member 35 i face of the part 33, it will be apparent that vided with a projection 58 of relatively small h rays ofa beam of light under like condidiameter, which is adapted to contact at its tleIlS Whleh imp g 1113011 the e ecting surupper end with the member 40 at the upper face of the part 32 Will be relatlvely widely end of the opening 54 in the lower end thereof. g sp' so that the b m which is reflected A strong spring GOjs coiled about the projec- IS 111 the Shape Of a Widening cone. By this tion 58 with its lower end seated against the means he presence of the sign or signal is upper side of the member35 and its upper end pp ent to persons who may occupy an auseated against the member 40 at, the upper tompblle 9 the hke not 9 3 when the slgn end f th opening 54 or slgnal is located a relatively great distance Normally and at the of an per- 1I1 fIOIllZ the aIItOIII'ObIlG but c1180 after the ation the upper end of the prqeetion 58 is automobile has reached a pOSltIOIl either (11- paced from the opposing portion of the rectly'ln front of the reflector or upon one member 40 at th upper d of th o ning slde or the other of a line extended axlally 54 therein. of the reflector.

In the operation of the die press shown in It i be e n tha by 111' inven ion W Fig. 8 the member 40 is moved downwardly are enabled to produce practically and at by means of usual construction (not shown) reasonable or minimum cost a reflector havprovided for that purpose, and initially the mg desirable characteristics of construction spring 60 operates to transmit pressure from as set-forth in our original application prethe member 40 to the member 35 to cause the 'viously referred to herein. 7 latter to act upon the upper closed end por- Having thus described our invention what tion of the reflector and press and draw the we claim and desire to' secure by Letters same so as to cause the inner portion of-the Patent is: flange surrounding the initially formed cup- 1. The method of producing a light relike'portion previously referred to to seat 'flector from sheet metal, which'comprises the upon the shoulder 44. Simultaneously the successive formation of cup-like members lower annular end portion of the member 40 having outwardly extending lateral flanges at its outer edges in a strip of sheet metal, subjecting the said cup-like members thus formed successively to the die members of a die press, and applying first a yielding pressure to the cup-like portion thereof and simultaneously an unyielding pressure to the flange portion, and finally applying to the cup-like portion an unyielding pressure force to give final shape tothe bottom of said cuplike member and to impart a high polish to the inner surface thereof.

2. The method of producing a light reflector from sheet metal which comprises the subjecting of sheet metal to pressure by means of dies to form a centrally located depression therein, applying a yielding presv sure to the depressed portion and simultaneously an unyielding pressure to the portion ofthe saidsheet surrounding the depressed portion, and finally applying to the bottom of the said depression an unyielding pressure force to give final shape thereto and to impart a high-polish to the interior surface thereof. 7

3. The method of producinga light reflector from sheet metal which comprises the subjecting of the same to forces extending in opposite directions transversely of the said sheet to form a centrally located depressed portion therein, thereafter initially subjecting the said centrally located depressed portion to compressive yielding pressure, simultaneously subjecting the portion of said sheet surrounding the said depressed portion to a positive unyielding pressure and finally subjecting the bottom of the centrally located depressed portion to unyielding pressure and thereby imparting to the inner surface thereof a polish which is light reflecting.

4. The method of producing a light reflector from sheet metal which comprises the formation by pressure in a piece of sheet metal of a centrally located depressed portion, thereafter applying an initially yielding compressive and drawing pressure to the said depressed portion and causing the provjection of a central portion of the bottom of the said depression to provide a depression upon the inner side of said bottom, simultaneously applying a positive unyielding pressure to the portion of said sheet surrounding-the said first named depressed portion and forming it into cylindrical shape in cross section and finally applying an unyielding'compressive pressure'to the bottom of the said depressed portion and thereby imparting to the inner surface thereof a polish which is light reflecting.

In testimony that we claim the foregoing as our. invention. we have hereunto signed our names this 22 day of Dec., A. D. 1930.

.RICHARD W. LUCE.

LESLIE M. MERRILL.

CERTIFICATE OF CORRECTION.

Patent No. 1,837,720. Granted December 22, 193] to RICHARD W. LUCE ET AL.

It is hereby certified that error appears in theprinted specification of the above numbered patent requiring correction as follows: Page 3, line 114, after the word "position" insert the words quite near to the said sign or signal and occupies a position; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 16th day of February, A. D. 1932.

M. I J. Moore,

(Seal) Acting Commissioner of Patents. 

